Finite Element Modelling and Investigation of the Process Parameters in Deep Rolling of AISI 4140 Steel

Lyubenova, Nataliya; Baehre, Dirk

doi:10.17265/2161-6221/2015.7-8.004

Cited by 7 publications

(3 citation statements)

References 8 publications

(7 reference statements)

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“…In general, the operation of deep rolling can be realized through two motions as follows: (a) immersing or pressing the roller or ball (which is free to revolve about its own axis) against the workpiece with a pre-determined force and (b) rotating workpiece on the lengthwise axis (for cylindrical parts) or in-plane translations (for flat parts). The numerous controlling parameters illustrated in Figure 3 show the deep rolling process and, consequently, the near-surface properties [23]. Therefore, identifying the optimum combination of these control parameters is crucial for achieving desirable surface property enhancement.…”

Section: Deep Rollingmentioning

confidence: 99%

“…N. Lyubenova and D. Bahre [23,141] extensively investigated the reliability of finite element modeling in estimating the residual stresses in AISI 4140 steel and reported the effect of variation in control parameters on the computed results through 3D explicit dynamics simulation in ABAQUS v6.14. Four different material models (elastic perfectly plastic, isotropic-plastic, bi-linear kinematic hardening, and Johnson-Cook models) with different combinations of controlling parameters (rolling pressure, number of passes, and percentage overlap) were considered in the study.…”

Section: Finite Element Modeling Of the Deep Rolling Processmentioning

confidence: 99%

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Deep Rolling Techniques: A Comprehensive Review of Process Parameters and Impacts on the Material Properties of Commercial Steels

Noronha,

Sharma,

Prabhu Parkala

et al. 2024

Metals

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The proposed review demonstrates the effect of the surface modification process, specifically, deep rolling, on the material surface/near-surface properties of commercial steels. The present research examines the various process parameters involved in deep rolling and their effects on the material properties of AISI 1040 steel. Key parameters such as the rolling force, feed rate, number of passes, and roller geometry are analyzed in detail, considering their influence on residual stress distribution, surface hardness, and microstructural alterations. Additionally, the impact of deep rolling on the fatigue life, wear resistance, and corrosion behavior of AISI 1040 steel is discussed. Engineering components manufactured by AISI 1040 steel can perform better and last longer when deep rolling treatments are optimized with an understanding of how process variables and material responses interact. This review provides critical insights for researchers and practitioners interested in harnessing deep rolling techniques to enhance the mechanical strength and durability of steel components across diverse industrial settings. In summary, the valuable insights provided by this review pave the way for continued advancements in deep rolling techniques, ultimately contributing to the development of more durable, reliable, and high-performance steel components in diverse industrial applications. The establishment of generalized standardizations for the deep rolling process proves unfeasible because of the multitude of controlling parameters and their intricate interactions. Thus, specific optimization studies tailored to the material of interest are imperative for process standardization. The published literature on the characterization of surface and subsurface properties of deep-rolled AISI 1040 steel, as well as process parameter optimization, remains limited. Additionally, numerical, analytical, and statistical studies and the role of ANN are limited compared with experimental work on the deep rolling process.

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Section: Deep Rollingmentioning

confidence: 99%

Section: Finite Element Modeling Of the Deep Rolling Processmentioning

confidence: 99%

Deep Rolling Techniques: A Comprehensive Review of Process Parameters and Impacts on the Material Properties of Commercial Steels

Noronha,

Sharma,

Prabhu Parkala

et al. 2024

Metals

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show abstract

“…Based on the above literature analysis, it is clear that the effects of deep-cold-rolling process parameters on the surface integrity of titanium alloys, magnesium alloys, and hardened steel have been explored (Ref 4,23,28,34,45,48,49). However, the literature on the effects of various deep rolling parameters on the surface integrity of AISI 4140 steel is limited (Ref 49,50). A survey in the literature also indicates that there are few investigations about the application of DOE methods for optimizing the process parameters for enhanced surface characteristics ( Ref 4,51).…”

Section: Introductionmentioning

confidence: 99%

Surface Properties and Corrosion Behavior of Turn-Assisted Deep-Cold-Rolled AISI 4140 Steel

Prabhu

Sharma

et al. 2020

J. of Materi Eng and Perform

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In this research, the effect of various turn-assisted deep-cold-rolling process parameters on the residual stress, microstructure, surface hardness, surface finish, and corrosion behavior of AISI 4140 steel has been investigated. The examination of the surface morphology of the turned and processed samples was performed by using a scanning electron microscope, energy-dispersive spectroscopy, and atomic force microscopy. Response surface methodology and desirability function approach were used for reducing the number of experiments and finding local optimized conditions for parameters under the study. The results from the residual stress measurements indicate that the rolling force has the highest effect by generating a deeper layer of residual compressive stress. The outcomes of surface hardness and surface finish emphasize that rolling force and number of tool passes are the most significant parameters affecting the responses. Surface studies confirmed the corrosion and its intensity onto the metal surface, and according to atomic force microscopy studies, the surface had become remarkably rough after exposure to the corrosive medium. Improvements in surface microhardness from 225 to 305.8 HV, the surface finish from 4.84 down to 0.261 μm, and corrosion rate from 6.672 down to 3.516 mpy are observed for a specific set of parameters by turn-assisted deep-cold-rolling process. The multiresponse optimization for surface finish and corrosion rate together shows that a ball diameter of 10 mm, a rolling force of 325.75 N, initial roughness of 4.84 µm, and number of tool passes of 3 give better values for the two responses under consideration with composite desirability of 0.9939. Based on the experimental work at the optimum parameter setting, the absolute average error between the experimental and predicted values for the corrosion rate is calculated as 3.2%.

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Numerical parameter sensitivity analysis of residual stresses induced by deep rolling for a 34CrNiMo6 steel railway axle

Pertoll,

Buzzi,

Leitner

et al. 2024

Int J Adv Manuf Technol

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To optimise the benefits of the deep-rolling process in the service life context of treated components, the process application must be investigated. In addition to the reduction in surface roughness and near-surface material strengthening, compressive residual stresses are introduced, which are primarily responsible for the increase in service life for components, especially in the case of high-strength steel materials. A numerical parameter sensitivity analysis is performed in order to investigate the introduced residual stresses in detail. For this purpose, a validated deep-rolling simulation model is used, which replicates the deep rolling of a railway axle made of the high-strength steel material 34CrNiMo6. The model is based on an elastic-plastic Chaboche material model parameterised on uniaxial tensile and LCF test results and validated with residual stress measurements. Using this model as a basis, the effect of the main process parameters deep-rolling force, feed rate, friction coefficient, number of overruns, tool geometry, and shaft geometry on the resulting residual stress state are investigated. The results reveal that the deep-rolling force has the most significant influence on the introduced residual stress state and should therefore be highlighted. In the case of applying a deep-rolling force of more than 10 kN, maximum compressive residual stresses of around − 1000 MPa are introduced, and a strong saturating behaviour is shown. Maximum compensating tensile residual stresses of + 100 MPa occur below the surface. The main influence of the deep-rolling force is the effective depth achieved, which is determined by the depth of the zero crossing. This varies from 1 mm with an applied force of 2 kN to more than 3.5 mm with 20 kN. Furthermore, the results are analysed to conclude suggestions for the process’s applicability, and a proposal for an optimised deep-rolling treatment is presented. There multiple deep rolling with decreased deep-rolling forces is used to achieve a comparably optimised residual stress state. In summary, with the presented results, a contribution to a deeper understanding of the deep-rolling process can be achieved; the influence of the most important process parameters on the residual stress in-depth profiles is established; an optimisation proposal is presented; and correlations are found. Thus, the base work for further fatigue strength assessments and the optimisation of the deep-rolling process regarding the increase of service is laid.

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Finite Element Modelling and Investigation of the Process Parameters in Deep Rolling of AISI 4140 Steel

Cited by 7 publications

References 8 publications

Deep Rolling Techniques: A Comprehensive Review of Process Parameters and Impacts on the Material Properties of Commercial Steels

Deep Rolling Techniques: A Comprehensive Review of Process Parameters and Impacts on the Material Properties of Commercial Steels

Surface Properties and Corrosion Behavior of Turn-Assisted Deep-Cold-Rolled AISI 4140 Steel

Numerical parameter sensitivity analysis of residual stresses induced by deep rolling for a 34CrNiMo6 steel railway axle

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